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Aluminum Pergolas

Every pergola we offer has a heavy-duty aluminum frame in all structural weight-bearing components, including all posts, beams and rafters. But unlike most pergola manufacturers who simply powder-coat the aluminum and call it good, we encase the aluminum frame in premium extruded vinyl "sleeves" that are guaranteed to never discolor, warp, chalk, pit or become brittle. So you get the strength & durability of an aluminum pergola plus the beauty & elegance of a vinyl pergola.

Choose which style of aluminum-frame pergola you'd like...

Why Are Aluminum Pergolas Superior to the Rest?

Aluminum-frame pergolas are:

• Rust-Proof - Unlike many other metals and alloys (including steel), aluminum does not rust.
• Strong - Aluminum has a perfect balance of malleability and strength. (Did you know that F-16 fighter jets have an 80% aluminum frame?)
• Lightweight - With a low density of only 2.7 g/cm³, aluminum is about 3x ligther than steel (but has a much higher strength-to-weight ratio than steel).

Thanks to these amazing attributes, our aluminum pergolas are guaranteed to never rust, break, sag, bow or bend over time — even in extreme weather conditions.

Because our aluminum-made pergolas (with vinyl sleeves) are fairly lightweight, we are able to span up to 22 feet between posts (columns). So as long as you plan to position the posts 12 inches in from the outside edges of the beams/rafters (which is the standard configuration for our traditional-style pergolas), your pergola can be up to 24' wide and 24' deep without needing a middle post. (Wood-frame pergolas, on the other hand, can typically only span 12 feet... half the distance!)

Why Not Just Powder-Coat the Aluminum Like Other Pergola Manufacturers Do?

Plain and simple... Powder-coated aluminum pergolas will start showing signs of age, weathering and corrosion after just a couple years. Even the very best powder-coated surfaces are prone to getting scratched and dinged. The initial "luster/shine" of a powder-coated aluminum pergola will also fade and become discolored, typically right around the time the meager 1- or 2-year warranty expires (which isn't a coincidence).

In contrast, we encase our aluminum pergolas in "sleeves" made of premium extruded vinyl. These sleeves are ultra-thick and colored throughout (not just the outer surface) and are guaranteed to never chalk, pit, discolor or become brittle. Sunset Pergolas will be just as beautiful in 30 years as they are on day 1.

Bottom line: If you buy a power-coated aluminum pergola, expect to replace it in 3-5 years. If you buy a Sunset Pergola, it will last for decades.

Which Pergola Components Have an Aluminum Frame Inside Them?

All structural, weight-bearing components of the pergola have aluminum frames inside them. This includes the posts (columns), the room beams, and the roof rafters. (The purlin holders and shade purlins do not have a metal frame in them, as they are non-weight-bearing and aluminum frames would only make the pergola heavier.)

How Thick (i.e. What Gauge) are the Aluminum Frames?

Two-post attached pergolas and 4-post freestanding pergolas up to 18' wide and 18' deep have:

• Aluminum posts & mounts - 4.6" square by 3.81mm thick (approximately 7-gauge aluminum - note: the lower the gauge number, the thicker & stronger it is)
• Aluminum roof beams - 2" x 6" rectangular tubing that is 1.65mm thick (16-gauge) on the 2" side and 2.03mm thick (12-gauge) on the 6" side
• Aluminum roof rafters - Same as beams

Two-post attached pergolas and 4-post freestanding pergolas that are 20-24' wide and up to 20-24' deep have:

• Aluminum posts & mounts - 4.6" square by 5.72mm thick (almost 2x thicker than 1-gauge aluminum)
• Aluminum roof beams - 2" x 8" rectangular tubing that is 2.50mm thick (10-gauge) on both sides
• Aluminum roof rafters - Same as beams

Three-post (or more) attached pergolas and 6-post (or more) freestanding pergolas will typically have the same aluminum components as the up-to-18' wide/deep pergolas (since the weight is distributed among a greater number of posts).